Generally used to produce a specific radius on a component in one operation, corner rounders can also remove burrs or sharp edges.
The pilot diameter significantly impacts the tool’s performance. Larger pilot diameters enable the tool to operate at lower speeds, while smaller ones allow for higher speeds due to their increased effective cutter radius. The effective cutter diameter can be calculated using these equations based on the radius-to-pilot ratio:
- Radius/Pilot Ratio < 2.5: Effective Cutter Diameter = Pilot Diameter + Radius
- Radius/Pilot Ratio ≥ 2.5: Effective Cutter Diameter = Pilot Diameter + 0.7x Radius
Larger pilot diameters offer enhanced strength compared to smaller ones, thanks to the extra material behind the radius. Smaller pilots may be required for clearance in narrow slots or holes, facilitating tighter turns when machining inside corners.